2016 YAMAHA WR 250F sensor

SPECIAL TOOLS
1-15
Pocket tester
90890-03112
Analog pocket tester
YU-03112-CThis tool is used to measure
the voltage, current, and re-
sistance of electrical compo-
nents.
Timing light
90890-03141
Timing light
YU-03141This tool is used to measure
the ignition timing.
Pressure gauge
90890-03153
Pressure gauge
YU-03153This tool is used to measure
the fuel pressure.
Fuel pressure adapter
90890-03186
Fuel pressure adapter
YM-03186This tool is used to mount the
pressure gauge.
Test harness S– pressure
sensor (3P)
90890-03207
Test harness S– pressure
sensor (3P)
YU-03207This tool is used to check the
throttle position sensor input
voltage.
Test harness– lean angle
sensor (6P)
90890-03209
Test harness– lean angle
sensor (6P)This tool is used to check the
lean angle sensor output volt-
age.
FI diagnostic tool sub–lead
90890-03212
FI diagnostic tool sub–lead
YU-03212This tool is used to connect
the Yamaha diagnostic tool
to a battery.
Test harness– speed sensor
5TJ (3P)
90890-03228
Test harness– speed sensor
5TJ (3P)
YU-03228This tool is used to check the
speed sensor output voltage.
Yamaha diagnostic tool
90890-03231
Yamaha diagnostic tool (US)
90890-03234This tool is used to check er-
ror codes or carry out self-di-
agnosis. Tool name/Part number How to use Illustration

ENGINE SPECIFICATIONS
2-6
Throttle body
Type/quantity 30RA-A95R/1
ID mark 2GB1 00
Fuel line pressure at idling 324.0 kPa (3.24 kgf/cm
2, 47.0 psi)
Throttle position sensor
Resistance 6.30 k
Output voltage (at idle) 0.5 V
Fuel injection sensor
Crankshaft position sensor resistance 228–342  (Gy–B)
Intake air pressure sensor output voltage 3.61–3.67 V at 101.3 kPa (3.61–3.67 V at 1.01
kgf/cm
2, 3.61–3.67 V at 14.7 psi)
Intake air temperature sensor resistance 290–390  at 80 °C (290–390  176 °F)
Coolant temperature sensor resistance 2.51–2.78 k at 20 °C (2.51–2.78 k at 68 °F)
210–221  at 100 °C (210–221  at 212 °F)
Idling condition
Engine idling speed 1900–2100 r/min
CO% 3.0–4.0 % (USA) (CAN)
Intake vacuum 25.3–29.3 kPa (190–220 mmHg, 7.5–8.7 inHg)
(USA) (CAN)
Water temperature 70.0–90.0 °C (158.00–194.00 °F)
Oil temperature 70.0–80.0 °C (158.00–176.00 °F)
Throttle grip free play 3.0–5.0 mm (0.12–0.20 in)

TIGHTENING TORQUES
2-15
TIP
Exhaust pipe nut
First temporarily tighten nuts to 13 Nm (1.3 m·kgf, 9.4 ft·lbf). Then retighten them to 20 Nm (2.0 m·kgf,
14 ft·lbf).Clutch boss nut M16 1 75 Nm (7.5 m·kgf, 54 ft·lbf)Use a
lock
washer.
Drive sprocket nut M18 1 75 Nm (7.5 m·kgf, 54 ft·lbf)Use a
lock
washer.
Segment
M8 1 30 Nm (3.0 m·kgf, 22 ft·lbf)
Shift guide bolt
M6 2 10 Nm (1.0 m·kgf, 7.2 ft·lbf)
Stopper lever bolt
M6 1 10 Nm (1.0 m·kgf, 7.2 ft·lbf)
Shift pedal bolt M6 1 12 Nm (1.2 m·kgf, 8.7 ft·lbf)
Rotor nut
M12 1 65 Nm (6.5 m·kgf, 47 ft·lbf)
Stator screw
M5 2 7 Nm (0.7 m·kgf, 5.1 ft·lbf)
Crankshaft position sensor bolt
M6 2 10 Nm (1.0 m·kgf, 7.2 ft·lbf)
Damper assembly cover bolt
M6 2 10 Nm (1.0 m·kgf, 7.2 ft·lbf)
Starter clutch bolt
M6 6 16 Nm (1.6 m·kgf, 12 ft·lbf)
Starter motor bolt
M6 1 12 Nm (1.2 m·kgf, 8.7 ft·lbf)
Coolant temperature sensor
M10 1 16 Nm (1.6 m·kgf, 12 ft·lbf)
Neutral switch bolt
M5 2 3.5 Nm (0.35 m·kgf, 2.5 ft·lbf)
Intake air temperature sensor screw
M5 1 1.5 Nm (0.15 m·kgf, 1.1 ft·lbf)
Rectifier/regulator bolt
M6 2 7 Nm (0.7 m·kgf, 5.1 ft·lbf)
ECU bolt
M5 2 3.8 Nm (0.38 m·kgf, 2.8 ft·lbf)
Ignition coil bolt
M6 2 7 Nm (0.7 m·kgf, 5.1 ft·lbf)
Throttle position sensor screw
M5 2 3.4 Nm (0.34 m·kgf, 2.5 ft·lbf)
Intake air pressure sensor screw
M6 1 5 Nm (0.5 m·kgf, 3.6 ft·lbf) ITEMThread
sizeQ’ty TIGHTENING TORQUES Remarks
LT
LT
LT
LT
LT
LT

TIGHTENING TORQUES
2-18
Drive chain tensioner bolt (lower
side)M8 1 16 Nm (1.6 m·kgf, 12 ft·lbf)
Drive chain support bolt M6 1 7 Nm (0.7 m·kgf, 5.1 ft·lbf)
Drive chain support nut M6 2 7 Nm (0.7 m·kgf, 5.1 ft·lbf)
Drive chain guide bolt M5 3 4.0 Nm (0.40 m·kgf, 2.9 ft·lbf)
Rear frame and left cover bolt M6 2 7 Nm (0.7 m·kgf, 5.1 ft·lbf)
Fuel tank bolt (front side) M6 2 7 Nm (0.7 m·kgf, 5.1 ft·lbf)
Fuel tank bolt (rear side) M6 1 9 Nm (0.9 m·kgf, 6.5 ft·lbf)
Fuel tank bracket bolt (front side) M6 4 7 Nm (0.7 m·kgf, 5.1 ft·lbf)
Fuel tank bracket bolt (rear side) M6 2 7 Nm (0.7 m·kgf, 5.1 ft·lbf)
Fuel pump bolt M5 6 4.0 Nm (0.40 m·kgf, 2.9 ft·lbf)
Fuel sender screw M6 2 4.0 Nm (0.40 m·kgf, 2.9 ft·lbf)
Fuel inlet pipe screw M5 2 3.4 Nm (0.34 m·kgf, 2.5 ft·lbf)
Fuel tank cap cover bolt M6 2 4.0 Nm (0.40 m·kgf, 2.9 ft·lbf)
Seat set bracket and fuel tank screw M6 1 7 Nm (0.7 m·kgf, 5.1 ft·lbf)
Seat bolt M8 2 22 Nm (2.2 m·kgf, 16 ft·lbf)
Left side cover bolt M6 1 7 Nm (0.7 m·kgf, 5.1 ft·lbf)
Right side cover bolt M6 2 7 Nm (0.7 m·kgf, 5.1 ft·lbf)
Frame and air scoop bolt M6 2 7 Nm (0.7 m·kgf, 5.1 ft·lbf)
Fuel tank and air scoop bolt M6 2 7 Nm (0.7 m·kgf, 5.1 ft·lbf)
Radiator guard and air scoop bolt M6 4 7 Nm (0.7 m·kgf, 5.1 ft·lbf)
Front fender bolt M6 4 10 Nm (1.0 m·kgf, 7.2 ft·lbf)
Rear fender bolt (front side) M6 4 7 Nm (0.7 m·kgf, 5.1 ft·lbf)
Rear fender bolt (rear side) M6 2 16 Nm (1.6 m·kgf, 12 ft·lbf)
Mud flap screw — 2 1.3 Nm (0.13 m·kgf, 0.94 ft·lbf)
Headlight body and headlight stay
boltM6 2 7 Nm (0.7 m·kgf, 5.1 ft·lbf)
Multi-function meter nut M5 2 3.8 Nm (0.38 m·kgf, 2.8 ft·lbf)
Multi-function meter bracket bolt M6 1 7 Nm (0.7 m·kgf, 5.1 ft·lbf)
Front brake hose guide and head-
light stay boltM5 1 3.8 Nm (0.38 m·kgf, 2.8 ft·lbf)
Plate 1 and front fork protector bolt M5 2 3.8 Nm (0.38 m·kgf, 2.8 ft·lbf)
Plate 2 and front fork protector
screw— 2 0.5 Nm (0.05 m·kgf, 0.36 ft·lbf)
Speed sensor lead holder and
speed sensor lead bracket boltM6 1 7 Nm (0.7 m·kgf, 5.1 ft·lbf)
Speed sensor lead bracket and low-
er bracket boltM6 1 13 Nm (1.3 m·kgf, 9.4 ft·lbf)
Starter relay and positive battery
lead boltM6 1 3.5 Nm (0.35 m·kgf, 2.5 ft·lbf) ITEMThread
sizeQ’ty TIGHTENING TORQUES Remarks

TIGHTENING TORQUES
2-19
TIP
Lower ring nut
1. First, tighten the lower ring nut approximately 38 Nm (3.8 m·kgf, 27 ft·lbf) by using the steering nut
wrench, then loosen the lower ring nut one turn.
2. Retighten the lower ring nut 7 Nm (0.7 m·kgf, 5.1 ft·lbf).Starter relay and starter motor lead
boltM6 1 3.5 Nm (0.35 m·kgf, 2.5 ft·lbf)
Lean angle sensor bolt M4 2 3.8 Nm (0.38 m·kgf, 2.8 ft·lbf)
Taillight assembly screw — 3 1.1 Nm (0.11 m·kgf, 0.80 ft·lbf)
Taillight lead clamp and rear fender — 3 0.5 Nm (0.05 m·kgf, 0.36 ft·lbf)
Battery bracket bolt M6 4 7 Nm (0.7 m·kgf, 5.1 ft·lbf)
Frame and battery negative lead
boltM6 1 7 Nm (0.7 m·kgf, 5.1 ft·lbf)
Rear fender and relay bracket screw — 2 1.1 Nm (0.11 m·kgf, 0.80 ft·lbf)
Front reflector nut (For Canada) M6 2 3.8 Nm (0.38 m·kgf, 2.8 ft·lbf)
Rear reflector nut (For Canada) M5 3 1.8 Nm (0.18 m·kgf, 1.3 ft·lbf)ITEMThread
sizeQ’ty TIGHTENING TORQUES Remarks

LUBRICATION POINTS AND LUBRICANT TYPES
2-21
EAS2GB7070CHASSISShift lever assembly moving parts
Damper assembly shaft, thrust surfaces, washers
Starter idle gear inner surface, thrust surfaces
Starter clutch drive gear inner surface, thrust surfaces
Cylinder head cover gasketThree bond
No.1215®
Crankcase mating surfaceThree bond
No.1215®
Stator assembly lead grommetThree bond
No.1215®
Lubrication point Lubricant types
Upper bearings (steering head)
Upper bearings and bearing race cover (steering head)
Lower bearings and oil seal lip (steering head)
Steering stem threads and nut contacting surface
Pivot shaft bearing
Swingarm pivot portion (collar side surface and thrust bearing)
Swingarm pivot portion (collar outer surface)
Swingarm pivot portion (oil seal lip)
Pivot shaft outer surface
Relay arm bearing and oil seal lip
Relay arm thrust washer surface (both sides)
Relay arm collar outer surface and bolt outer surface
Relay arm bolt threads (swingarm side)
Connecting arm bearing and oil seal lip
Connecting arm collar outer surface and bolt outer surface
Rear shock absorber assembly collar outer surface and dust seal lip (upper
side)
Rear shock absorber assembly bearing and dust seal lip (lower side)
Brake pedal pivot portion (O-ring and bolt outer surface)
Front wheel oil seal lip
Front wheel axle outer surface
Speed sensor oil seal lip
Rear wheel oil seal lip
Rear wheel axle outer surface
Sidestand pivot portion and collar outer surface
Brake lever contacting portion (front brake master cylinder)
Front brake lever bolt outer surface
Clutch lever sliding surface and bolt outer surfaceLubrication point Lubricant types
E
E
E
E
LS
LS
LS
LS
M
M
M
M
M
M
M
M
M
M
M
M
M
LS
LS
LS
LS
LS
LS
LS
S
S
LS

CABLE ROUTING DIAGRAM
2-32
1. Clutch cable
2. Throttle cable (return)
3. Throttle cable (pull)
4. Engine stop switch lead
5. Coupler for connecting optional part
6. Engine stop switch coupler
7. Rectifier/regulator coupler
8. AC magneto lead
9. Starter knob/idle screw
10. Starter motor lead
11. Radiator fan fuse
12. Taillight
13. Headlight relay (yellow tape)
14. Starting circuit cut-off relay (no identification
tape)
15. Diode
16. Holder plate
17. Left of the vehicle:radiator fan motor relay (blue
tape)
Right of the vehicle:main relay (red tape)
18. Neutral switch lead
19. Engine bracket
20. Front engine bracket
21. Plastic locking tie
22. Radiator hose
23. Neutral switch coupler
24. Crankshaft position sensor coupler
25. Tension arm
26. Wire harness
27. Tank rail
28. Rectifier/regulator
29. Rectifier/regulator bracket
30. Rear frame
31. Side cover 5
32. Crankcase cover
33. Crankcase
34. Lead holder
35. Frame
A. Pass the engine stop switch lead between the
frame and the cable holder.
B. Insert the coupler for connecting optional part into
the connector, and fix it to the bracket.
C. Insert and fix the engine stop switch coupler to
the bracket.
D. Insert and fix the rectifier/regulator coupler to the
bracket.
E. Pass the AC magneto lead to the front of the ve-
hicle beyond the starter knob/idle screw and to
the rear of the vehicle beyond the radiator. No
pinch is allowed between the radiator and the
tension arm.
F. Place the rear grommet of the starter motor lead
matching the rear end of the side cover.
G. Insert the radiator fan motor fuse into the protru-
sion of the holder plate.
H. Place the diode on top of the rear fender on the
inner side of the rear frame.
I. Bring the neutral switch lead into line with the
crankcase cover with no sag allowed.
J. Route the AC magneto lead under the starter
clutch cover.
K. Pass the neutral switch lead to the inside of the
front engine bracket (the side of the vehicle).
L. Insert the plastic locking tie into the bracket hole
and clamp the clutch cable. Clamp it so that the
lock of the plastic locking tie faces downward,
and then cut off the end of the plastic locking tie.
M. Pass the clutch cable with no downward sag al-
lowed.N. Place the grommet of the clutch cable so that it
contacts the radiator hose. Route the clutch cable
outside the neutral switch lead, AC magneto lead
and starter motor lead.
O. Route each lead so that the leads are not pinched
between the radiator hose and the frame.
P. 40 mm (1.57 in)
Q. Clamp the clutch cable, AC magneto lead, neu-
tral switch lead and starter motor lead by the plas-
tic locking tie. Make sure that they are clamped at
the positioning tapes in the clutch cable and the
starter motor lead. Make the lock on the plastic
locking tie face the front of the vehicle, and cut
the end.
R. Clamp the starter motor lead to the inside of the
tension arm with a plastic locking tie. Clamp it so
that the lock of the plastic locking tie faces up-
ward and outward, and do not cut off the end of
the plastic locking tie. Route the lead so that there
is no slack at the bottom from the clamp position
onwards.
S. After connecting the neutral switch coupler, at-
tach the coupler cover.
T. After connecting the crankshaft position sensor
coupler, attach the coupler cover.
U. Pass the rectifier/regulator lead to the inside of
the tension arm (the side of the vehicle).
V. Pass the main harness to the front of the radiator
hose (the front of the vehicle), and to the inside of
the clutch cable (the side of the vehicle).
W. Pass the engine stop switch lead between the
coupler for connecting optional part and the tank
rail, with the lead on the main harness side facing
the top of the vehicle.
X. Insert the starter motor lead completely into the
end of the side cover 5.
Y. Clamp the clutch cable at the front of the lead (the
front of the vehicle).
Z. Insert the clip of the plastic locking tie into the
frame. Face the lock of the plastic locking tie for-
ward, and then cut off the end.

CABLE ROUTING DIAGRAM
2-34
1. Clamp
2. Cylinder head breather hose
3. Throttle position sensor lead
4. Joint coupler
5. Intake air temperature sensor coupler
6. Intake air pressure sensor lead
7. Wire harness
8. Injector lead
9. Throttle body
10. Injector coupler
11. Starter motor lead
12. Plastic band
13. Fuel sender coupler
14. High tension cord
15. Spark plug cap
16. Cylinder head cover
17. Fuel hose
18. Fuel sender
19. Sub-wire harness
20. Crankcase breather hose
21. Radiator breather hose
22. Radiator hose
23. Down tube
24. Starter motor
25. Neutral switch lead
26. AC magneto lead
27. Clutch cable
28. Radiator
29. Air filter case breather hose
30. Breather hose clamp
31. Grommet (high tension cord)
32. ECU
33. Air filter case
34. Sub-wire harness coupler
35. Engine bracket
A. Fix the wire harness, clutch switch lead and start
switch lead by the plastic clamp, and insert the
projection of the plastic clamp into the hole in the
sheet metal of the radiator.
B. Route each lead so that the leads are not pinched
between the tank rail and air filter joint.
C. Insert the projection of the wire harness into the
hole in the frame.
D. Route the cylinder head breather hose without it
crossing the starter motor lead.
E. Pass the cylinder head breather hose between
the throttle cable and rectifier/regulator lead.
F. Connect the sub-wire harness to the wire har-
ness.
G. Pass the high tension cord above the fuel hose.
H. ±10°
I. Install the spark plug cap with this facing the right
of the vehicle.
J. Push the spark plug cap home, where there shall
be no gap between it and the cylinder head cover.
K. Pass the radiator breather hose between the
down tubes.
L. 50±3 mm (2.0±0.12 in)
M. Apply adhesive to the slit and inside of the grom-
met, and then fix the grommet according to the
specified dimensions.
N. Pass the sub-wire harness between the ECU and
the air filter case.
O. Insert the coupler of the sub-wire harness into the
rib of the air filter case.
P. Route the radiator breather hose through be-
tween the radiator hose, down tube and engine
bracket.